Fibre mat and products containing fibre mats

ABSTRACT

A hybrid fibre mat comprises glass fibres, polymer fibres and binding agents, the glass fibres having a mean diameter of between 6 and 13 μm and a mean length of between 6 and 15 mm, the polymer fibres being staple fibres having a mean fineness of between 0.2 and 0.6 dtex and a mean length of between 2 and 4 mm and the percentage by weight of the polymer fibres being between 5 and 20% of the dry fibre mat. Such a hybrid fibre mat being suitable in particular as a covering for interior elements, a ceiling panel or other interior cladding elements and, provided with an impregnation (for example plastisol), in particular as a structural layer of a cushioned vinyl floor covering. For the production thereof, preferably water which contains the glass fibres and the polymer fibres is passed in a circuit through a band screen, the fibre mixture in the form of a fibre layer with a predetermined layer thickness is deposited on the band screen, excess circuit water is removed from the fibre layer, binding agent is added to the fibre layer and the fibre layer to which binding agent has been added is dried.

BACKGROUND OF THE INVENTION

The present invention relates to a fibre mat. The invention further relates to products containing fibre mats, in particular a cushioned vinyl floor covering which comprises a fibre mat as a structural layer.

Fibre mats are known in many different embodiments and for various applications. For example, glass fibre mats are widely available. Different methods exist for the production thereof from glass fibres and binding agents.

A principal application of fibre mats is the use as a carrier material in floor coverings, namely in CV (cushioned vinyl) floor coverings. The fibre mats used here typically consist of glass fibres, the use of specific mixtures of different glass fibres also being known for producing corresponding glass fibre mat carriers (see DE 102011011056 A1, the disclosure thereof being made for the contents of the present application).

BRIEF SUMMARY OF THE INVENTION

The object of the present invention is to provide a fibre mat which is able to be produced in a cost-effective manner and which, due to properties which in this respect are particularly advantageous, is suitable, in particular, for the application as a carrier material in floor coverings and in this application advantageously influences the properties of the finished floor covering.

DETAILED DESCRIPTION OF THE INVENTION

This object is achieved according to the present invention, as set forth in claim 1, by a fibre mat which is designed as a hybrid fibre mat, by said mat comprising glass fibres, polymer fibres and binding agents, the glass fibres having a mean diameter of between 6 and 13 μm and a mean length of between 6 and 15 mm, the polymer fibres being staple fibres having a mean fineness of between 0.2 and 0.6 dtex and a mean length of between 2 and 4 mm and the percentage by weight of the polymer fibres being between 5 and 20% of the dry fibre mat.

In other words, therefore, a specific combination of synergistically interacting features is characteristic of the fibre mat according to the invention, such that both with regard to the material and with regard to the typical length and thickness dimensions said fibre mat consists of various fibres connected together by means of a binding agent, namely relatively short and—in the polymers principally under consideration here for the polymer fibres, with thicknesses of between approximately 1.2 and 1.6 g/cm³—thinner polymer fibres, on the one hand, and relatively long and thicker glass fibres, on the other hand, the percentage by weight of the polymer fibres being substantially less than the percentage by weight of the glass fibres, the polymer fibres only constituting between 5 and 20, preferably between 10 and 15 percentage by weight of the dry fibre mat. The ratio between the percentage by weight of the glass fibres and that of the polymer fibres in the fibre mat is typically between 5 and 8, for example approximately 6.5—with a percentage by weight of the binding agent of approximately between 20 and 30%.

Surprisingly, the hybrid fibre mat according to the invention is characterised by a series of very advantageous properties. Thus, due to the particular mixture of specific glass fibres used and specific polymer fibres, physical properties (mechanical strength, density, pore volume, hollow structure, etc.) are produced, such that particularly thin hybrid fibre mats according to the invention already satisfy the requirements which are applicable, in particular, to the structural materials of floor coverings. This is specifically an advantage which is not to be underestimated, therefore, as in this manner (already due to the reduced thickness of the fibre mat) the quantity of impregnating agent with which the fibre mat is to be treated may be reduced. This results in corresponding economic advantages relative to the prior art and namely without adversely affecting the performance. In contrast, the fibre mat according to the invention has a surface structure of particular quality and homogeneity, such that a floor covering produced by the application thereof is also characterised by a particular surface quality. This is a great advantage for surface finishing, namely by printing.

In other words, the present invention provides outstanding fibre mats with regard to the properties thereof and namely—for example an additional coating of the fibres, which is a drawback in terms of material expenditure and complexity of method, may be avoided—with minimal cost and without the use of respirable micro-glass fibres which are dangerous to the health.

Although the use of the hybrid fibre mat according to the invention is paramount when producing floor coverings, as far as the particular suitability of the hybrid fibre mat according to the invention is concerned, this does not constitute in any way the only possible use. Various features set forth above which characterise the hybrid fibre mat according to the invention are also able to be used particularly advantageously for a series of other applications. Here may be cited in particular the use as a paintable ceiling and wall covering (corresponding to a conventional wallpaper), in which due to the properties of the hybrid fibre mat an excellent surface quality may be achieved with a very small (subsequent) application of paint, moreover the exceptionally low tendency for the paint to pass through the fibre mat having a very advantageous effect on the adhesion of the hybrid fibre mat as a ceiling covering and/or wall covering on the relevant substrate. The fact that a very good surface quality may be achieved with a very small quantity of wall and/or ceiling paint is not only an economic aspect in this case. The weight of the ceiling covering and wall covering, together with the coat of paint, i.e. the painted ceiling covering and wall covering, also remains relatively low, which in turn assists the adhesion of the hybrid fibre mat onto the substrate. When using the hybrid fibre mat according to the invention as a visible face of a ceiling panel, a mineral coating is advantageously used.

These advantageous aspects apply in a very similar manner when using the hybrid fibre mat according to the invention as a surface coating of a construction panel, in particular a mineral ceiling panel or wall panel, such that the hybrid fibre mat is applied to the preformed panel in the factory (in particular by adhesive bonding and/or laminating); the specific structure of the hybrid fibre mat according to the invention thus prevents the penetration of the adhesive from the rear face to the front surface, i.e. the visible face, so that the surface quality of the visible face and the paint adhesion are not adversely affected by traces of adhesive. In addition, due to its advantageous properties, as set forth, the hybrid fibre mat according to the invention may be used particularly advantageously as a covering for interior elements, in particular as a ceiling panel or other interior cladding element.

With regard to production technology, it is advantageous if the polymer fibres consist of a polymer with a density of approximately 1.2 and 1.6 g/cm³. It is particularly advantageous if the polymer fibres consist entirely or at least substantially of PET (polyethylene terephthalate). When using such a material for producing the polymer fibres, said polymer fibres have such properties which are suitable for the production of the mat, the production of pure glass fibre mats providing experience thereof. In this sense, according to a preferred feature of the present invention, the hybrid fibre mat according to the invention is produced by the glass fibres and the water containing the polymer fibres being passed in a circuit through a band screen, the fibre mixture in the form of a fibre layer with a predetermined layer thickness then being deposited on the band screen, excess circuit water being removed from the fibre layer, binding agent being added to the fibre layer and the fibre layer to which binding agent has been added being dried.

The particular advantages set forth above of the glass fibre mat according to the invention are particularly pronounced when the mean fineness of the polymer fibres is between 0.3 and 0.4 dtex. Excellent results may be achieved, for example, by using PET fibres with a fineness of 0.33 dtex and a mean length of between 2.5 and 3.5 mm.

Moreover, according to a further preferred development of the present invention, it is particularly advantageous if the mean fibre diameter of the glass fibres is between 7 and 10 μm and/or the mean length of the glass fibres is between 7 and 9 mm. Specifically in combination with the preferred dimensions of the polymer fibres, as set forth above, particularly outstanding material properties result, which make the corresponding hybrid fibre mat particularly attractive for the applications set forth above. For different applications it is advantageous if the glass fibres are not longer than 15 mm and not thicker than 10 μm; since in the case of dimensions above these values the surface properties of the hybrid fibre mat are impaired. Particularly preferably, the glass fibres consist of C-glass and/or E-glass.

According to a further preferred development of the present invention—for typical applications of the hybrid fibre mat according to the invention—the surface weight of the glass fibre mat is between 25 and 80 g/m², particularly preferably between 40 and 60 g/m². Once again, in this case quite particularly advantageous properties of the hybrid fibre mat according to the invention result, in particular with regard to the possible use thereof as a carrier material in cushioned vinyl floor coverings with outstanding properties.

There is considerable flexibility here as regards the binding agent of the hybrid fibre mat according to the invention, which in particular may take into account the subsequent use of the hybrid fibre mat according to the invention. Particularly advantageous binding agents are urea resins and polyacrylic acid binders. The binding agent may, however, also comprise polyacrylic acid. Outstanding properties result when the binding agent comprises a mixture of urea resin and a polymer dispersion or a mixture of polyacrylic acid binders and a polymer dispersion.

Likewise, there is considerable flexibility as regards the percentage by weight of the binding agent in the hybrid fibre mat, in this regard the specific binding agent respectively used and also the use of the hybrid fibre mat also being able to play a role. For the potential use as a carrier material of a cushioned vinyl floor covering, which is paramount here, a percentage by weight of the binding agent of between 15% and 35%, preferably between 20% and 30% of the total weight of the hybrid fibre mat is advantageous.

The binding agent, depending on the designated subsequent use of the respective hybrid fibre mat according to the invention, may contain an additive (or a plurality of additives) which may constitute up to 50% of the total weight of the binding agent. The additive(s) may in this case specifically modify and/or optimise the properties of the binding agent with regard to the individual purpose of the hybrid fibre mat. Typical additives are, for example, kaolin and TiO₂. However, additives are not only capable of optimising the binding agent in technical terms but additives are also capable of reducing costs by being able to reduce the need for expensive binding agents.

The present invention according to the above embodiments does not relate exclusively to the untreated hybrid fibre mat. On the contrary, the invention also relates, in particular, to a hybrid fibre mat pre-treated for subsequent specific further processing, in particular provided with an additional impregnation, the impregnating agent, in particular, being able to be plastisol or another PVC-based agent. Moreover, the present invention also extends to the finished cushioned vinyl floor covering produced using the hybrid fibre mat according to the invention, said cushioned vinyl floor covering comprising a useable layer and a structural layer, the structural layer comprising a hybrid fibre mat according to the invention provided with an impregnation (see above). 

1. Fibre mat, namely hybrid fibre mat comprising glass fibres, polymer fibres and binding agents having the following features: the glass fibres have a mean diameter of between 6 and 13 μm and a mean length of between 6 and 15 mm; the polymer fibres are staple fibres having a mean fineness of between 0.2 and 0.6 dtex and a mean length of between 2 and 4 mm; the percentage by weight of the polymer fibres is between 5 and 20% of the dry fibre mat.
 2. Hybrid fibre mat according to claim 1, characterised in that the percentage by weight of the binding agent is between 15 and 35% of the dry fibre mat.
 3. Hybrid fibre mat according to claim 2, characterised in that the percentage by weight of the binding agent is between 20 and 30% of the dry fibre mat.
 4. Hybrid fibre mat according to claim 1, characterised in that the polymer fibres have a mean fineness of between 0.3 and 0.4 dtex.
 5. Hybrid fibre mat according to claim 1, characterised in that the polymer fibres have a mean length of between 2.5 and 3.5 mm.
 6. Hybrid fibre mat according to claim 1, characterised in that the polymer fibres consist of PET.
 7. Hybrid fibre mat according to claim 1, characterised in that the glass fibres have a mean diameter of between 7 and 10 μm.
 8. Hybrid fibre mat according to claims 1, characterised in that the diameter of the glass fibres is a maximum of 10 μm and in that the length of the glass fibres is a maximum of 15 mm.
 9. Hybrid fibre mat according to claim 1, characterised in that the glass fibres have a mean length of between 7 and 9 mm.
 10. Hybrid fibre mat according to claim 1, characterised in that the binding agent comprises urea resin, preferably a mixture of urea resin and a polymer dispersion.
 11. Hybrid fibre mat according to claim 1, characterised in that the binding agent comprises polyacrylic acid binders, preferably a mixture of polyacrylic acid binders and a polymer dispersion.
 12. Hybrid fibre mat according to claim 1, characterised in that the glass fibres consist of C-glass and/or E-glass.
 13. Hybrid fibre mat according to claim 1, characterised in that it has a surface weight of between 25 g/m² and 80 g/m², preferably of between 40 g/m² and 60 g/m².
 14. Hybrid fibre mat according to claim 1, characterised in that the percentage by weight of the polymer fibres is between 10 and 15% of the dry fibre mat.
 15. Hybrid fibre mat according to claim 1, characterised in that it is provided with an additional impregnation.
 16. Hybrid fibre mat according to claim 15, characterised in that the impregnating agent is plastisol.
 17. Cushioned vinyl floor covering having a useable layer and a structural layer, the structural layer comprising a hybrid fibre mat provided with an impregnation according to claim 15 or claim
 16. 18. Use of a hybrid fibre mat according to claim 1, as a covering for interior elements, in particular as a ceiling panel or other interior cladding element.
 19. Use of a hybrid fibre mat according to claim 1, as a surface coating of a construction panel, in particular a mineral ceiling panel or wall panel.
 20. Use of a hybrid fibre mat according to claim 1, as a wall covering.
 21. Method for producing the hybrid fibre mat according to claim 1, water, which contains the glass fibres and the polymer fibres, being passed in a circuit through a band screen, the fibre mixture, in this case in the form of a fibre layer with a predetermined layer thickness, being deposited on the band screen, excess circuit water being removed from the fibre layer, binding agent being added to the fibre layer and the fibre layer to which binding agent has been added being dried. 